Metal supported silica based catalytic membrane reactor assembly

ABSTRACT

A catalytic membrane reactor assembly for producing a hydrogen stream from a feed stream having liquid hydrocarbons, steam, and an oxygen source through the use of an autothermal reforming reaction, a water-gas-shift reaction, and a hydrogen permeable membrane.

TECHNICAL FIELD OF THE INVENTION

The present invention relates to the formulation of autothermal reforming (ATR) catalytic structures that are useful for hydrogen generation from liquid fuel hydrocarbons.

BACKGROUND OF THE INVENTION

With stricter environmental regulations on transportation fuels, coupled with higher level of heavier crude oil processing, demand for hydrogen in refineries is expected to increase in order to meet the need for more hydrotreating and hydrocracking processes. Today, about 95% of hydrogen is supplied by large-scale steam reforming of natural gas, which employs reforming, water-gas-shift (WGS), and pressure adsorption, processes in successive steps. Efficiency, however, suffers for smaller scale operations. Therefore, hydrogen production at a smaller scale from fossil fuels necessitates further development to meet the requirements of purity, economics and versatility for a variety of emerging applications such as the use of fuel cell powered vehicles.

During the last decade, there have been growing concerns about the shortage of energy supply in the world. Fuel cell technologies that use hydrogen may offer potentially non-polluting and efficient fuel for today's rising energy demands. While this type of technology is in development for renewable sources of hydrogen, hydrogen is typically commercially produced through conversion of hydrogen rich energy carriers.

Therefore, cost effective methods for the production of hydrogen from fossil fuels are becoming increasingly important, and more particularly, methods for the production of low cost, pure hydrogen, which is free from carbon monoxide are needed.

Hydrocarbon steam reforming (SR), partial oxidation (PDX) and autothermal reforming (ATR) are important known processes for hydrogen production. Steam reforming of high molecular weight hydrocarbons has been practiced for over 40 years in locations where natural gas is not available. ATR of higher hydrocarbons, however, is preferable to SR because it combines a highly endothermic SR process with an exothermic PDX process. This means that ATR is a more thermally stable process than SR and can be driven to thermo-neutral conditions. In addition, the start up of the ATR is more rapid than SR.

Noble metal based catalysts, particularly Rh-based catalysts, are active in the reforming of hydrocarbons to synthesis gas. Unlike conventional nickel catalysts, the Rh-based catalysts tolerate the presence of sulfur and prevent coke deposition, these being desirable properties for any reforming catalyst that is used with a commercial fuel as a feedstock. Commercial fuels typically contain sulfur that cannot be completely removed, as the sulfur may be present in an aromatic ring. Furthermore, with certain commercially available catalysts, sulfur deposition can also induce coke accumulation. Another significant drawback to catalysts that include noble metals is their cost, as compared with non-noble metal based catalysts. For example, the price of rhodium has risen almost 10 fold over the past 3 years from an average of about USD $16.77 per gram to about $149.71 per gram in 2010.

Steam reforming of methane is typically used as a form of catalytic reaction for the production of hydrogen. Conventional catalytic systems utilizing either nickel or noble metal catalysts for the steam reforming of methane require primary reaction temperatures of the order of about 700° C. and above, followed by rather extensive and expensive purification processes to provide a hydrogen product with reasonable purity (i.e., greater than 95% by volume) that can be used as a feed stock for many common processes.

Reforming of hydrocarbons other than methane, notably oil products, can be achieved with reactions similar to steam reforming of natural gas. The successive breaking of the C—C terminal bonds of higher hydrocarbons (i.e., hydrocarbons having at least 2 carbon atoms present) with suitable catalysts is more difficult than for methane; however, due to differences in reaction rates and increased propensity for thermal cracking (also called pyrolysis). To avoid the issues related to differing reaction rates and thermal cracking, carbon stripping is usually done in a separate pre-reformer, making this option of producing hydrogen more complex and more expensive than natural gas reforming.

Hydrogen can also be produced from non-volatile hydrocarbons such as heavy oils by gasification or partial oxidation. Gasification processes utilize steam at temperatures above about 600° C. to produce hydrogen whilst carbon is oxidized to CO₂. Gasification, however, is usually not economical compared to steam reforming and partial oxidation processes. By comparison, partial oxidation is a considerably more rapid process than steam reforming. In partial oxidation, the hydrocarbon feed is partially combusted with oxygen in the presence of steam at a temperature of between about 1300° C. and 1500° C. Pressure has little effect on the reaction rate of the process and is usually performed at pressures of about 2 to 4 MPa to permit the use of more compact equipment and compression cost reduction. When air is used as the oxygen source, nitrogen must be removed from the resulting hydrogen gas product, typically requiring a separate stage following the oxidation reactor. Partial oxidation is thus more suitable for small scale conversion, such as in a motor vehicle that is equipped with fuel cells. The process can be stopped and started, as required for on-board reformation, and when in progress, it can provide elevated temperatures that may start steam reforming along with the oxidation processes. This is called autothermal reforming and involves all the reactions mentioned so far.

The water-gas-shift (WGS) reaction is an alternative hydrogen production technology frequently used following a primary catalytic reaction utilized to remove carbon monoxide impurities and increase overall hydrogen yield. The WGS reaction is mildly exothermic and is thus thermodynamically favored at lower temperatures. The kinetics of the reaction, however, are superior at higher temperatures. Therefore, it is common practice to first cool the reformate product from the reformer in a heat exchanger to a temperature between about 350° C. and 500° C., and then conduct the reaction over a suitable WGS catalyst. The resulting reformate is then cooled once again to a temperature between about 200° C. and 250° C. and then reacted on a low temperature designated WGS catalyst. Due to these several conversion and heat exchanging steps involved, however, the process is economically expensive and highly inefficient.

Pressure Swing Adsorption (PSA) is a well-known established method to separate hydrogen from a stream containing impurities. PSA employs multiple beds, usually two or more, of solid adsorbents to separate the impure hydrogen stream into a very pure (99.9%) hydrogen product stream and a tail gas stream that includes the impurities and a fraction of the hydrogen produced. As an example, synthesis gas (H₂ and CO) may be introduced into one bed where the impurities, rather than the hydrogen, are adsorbed onto the adsorbents. Ideally, just before complete loading is achieved, this adsorbent bed is switched offline and a second adsorbent bed is placed on line. The pressure, on the loaded bed is subsequently reduced, which liberates the adsorbed impurities (in this case predominantly CO₂) at low pressure. A percentage of the inlet hydrogen, typically approximately 15 percent, is lost in the tail gas. A significant disadvantage of the PSA is that low tail gas pressure essentially limits the system to a single WGS stage. Limiting a hydrogen separation system to a single WGS stage thus decreases the amount of CO conversion as well as the total amount of hydrogen recovery. PSA is also undesirable, as compared to the use of membranes, in part due to the mechanical complexity of the PSA, which leads to higher capital and operating expenditures and potentially increased downtime.

Hydrogen is produced and removed through hydrogen permeable metal membranes, such as palladium or palladium, alloys. Metallic membranes, particularly palladium or palladium alloys, however, are very expensive, sensitive to sulfur compounds, and difficult to co-sinter with or sinter onto a catalyst layer. Additionally, such devices produce hydrogen using only the WGS reaction.

Another type of membrane is the so-called dense protonic ceramic membrane for hydrogen separation and purification. It is based on the use of single-phase and mixed-phase perovskite-type oxidic protonic ceramic membranes for separating or decomposing hydrogen containing gases or other compounds to yield a higher value product. However, these membranes suffer many of the shortcomings noted previously.

Thus, it is highly desirable to develop membrane reactors that are capable of converting liquid hydrocarbons into high purity hydrogen in a single step.

SUMMARY OF THE INVENTION

The present invention is directed to an apparatus and method that satisfies at least one of the needs described above. Broadly, this invention is directed to a catalytic membrane reactor (CMR) assembly that includes an autothermal reforming (AIR) catalyst, a water-gas-shift (WGS) catalyst, and a membrane that is permeable to hydrogen, wherein the CMR assembly is operable to convert a liquid hydrocarbon into hydrogen.

In one embodiment of the invention, the CMR assembly includes a ceramic tubular support having a porous structure, an autothermal reforming (ATR) catalytic structure disposed throughout an inner surface layer of the porous structure of the ceramic tubular support, a water-gas-shift (WGS) catalytic structure disposed throughout the inner surface layer of the porous structure of the ceramic tubular support, a γ-alumina layer disposed on an outer surface of the ceramic tubular support, and a membrane layer disposed on an outer surface of the γ-alumina layer, wherein the membrane layer is selectively permeable to hydrogen. Preferably, the ATR catalytic structure includes ATR mixed metal oxides, and the WGS catalytic structure includes WGS mixed metal oxides. Additionally, the γ-alumina layer can include a porous structure. Preferably, the ATR catalytic structure, in combination with the WGS catalytic structure, is operable to react with a feed stream that is made up of liquid hydrocarbon, steam, and an oxygen source to form hydrogen through a combination of ATR and WGS reactions. The produced hydrogen is recovered in the permeate stream, and carbon dioxide, along with unreacted feed stream is recovered in the retentate stream. In some embodiments, carbon monoxide can be recovered in the retentate stream as well.

In another embodiment, the CMR assembly can also include a cylindrical, stainless steel vessel having the ceramic tubular disposed therein, a pair of shells disposed on each, end of the stainless steel vessel. The shells are preferably high temperature material shells that provide for sealing, manifolding, expansion support, separated regions for the catalytic reactions, delivery of pressurized feed stream, support of the membrane, and/or removal of product gases. In another embodiment, the CMR assembly can include a feed input that is operable to receive the feed stream and operable to introduce the feed stream to the inner surface layer of the ceramic tubular support. In another embodiment, the CMR assembly can include a sweep stream input, a permeate output, and a retentate output. The sweep stream input is operable to receive a gaseous sweep, stream that is operable to remove the permeate stream from the CMR assembly. The permeate output is operable to receive the permeate stream, and the retentate output is operable to receive the retentate stream. In embodiments where the permeate stream and/or the retentate streams are removed from the CMR assembly, the forward reaction becomes favored, thereby resulting in an increase in production of hydrogen.

In another embodiment, the membrane layer includes a silica layer that is doped with metal. In one embodiment, the silica layer metal dopant can be selected from the group consisting of cobalt, iron, niobium, and combinations thereof.

In another embodiment, the ATR catalytic structure and the WGS catalytic structure each include nanoparticles. In another embodiment, the ATR catalytic structure can include mixed metal oxides, wherein the mixed metal oxides include a metal selected from the group consisting of rhodium, platinum, nickel, ruthenium, palladium, rhenium, iridium, gold, osmium, copper, zinc, iron, and combinations thereof. In another embodiment, the WGS catalytic structure can include mixed metal oxides, wherein the mixed metal oxides include a metal selected from the group consisting of copper, zinc, iron, and combinations thereof.

In an embodiment of the present invention, the ATR catalytic structure does not include a precious metal. In another embodiment, the WGS catalytic structure does not include a precious metal. In another embodiment, the CMR assembly does not include a reformats cooler.

In one embodiment of the present invention, the ceramic tubular support can include an α-alumina tube. In yet another embodiment, the α-alumina tube can have a porosity of about 30 to 40%. In yet another embodiment, the α-alumina tube can have an average pore size of between about 0.5 and 1 micron. In yet another embodiment, the γ-alumina layer can have an average pore size of about 4 nm.

In another embodiment of the present invention, a method for formulating a CMR assembly having an autothermal reforming (ATR) catalytic structure is provided. The method can include the steps of introducing an α-alumina membrane tube into a boehmite sol-gel for a sufficient period of time to allow the boehmite sol-gel to adequately coat the α-alumina membrane tube, removing the α-alumina membrane tube from the boehmite sol-gel and allowing the boehmite coated α-alumina membrane tube to dry, calcining the boehmite coated α-alumina membrane tube at a temperature within, a range from 450° C. to 600° C. until a bimodal distribution of α and γ-alumina phases form to yield a calcined membrane tube, obtaining a solution comprising an ATR catalyst, the solution comprising mixed metal oxide nanoparticles suitable for use as catalysts for an autothermal reforming process, soaking the calcined membrane tube in a metal doping solution to form an activated catalytic support, and doping an outer surface of the activated catalytic support with a silica colloidal sol-gel to produce a hydrogen permeable layer on the outer surface of the activated catalytic support to produce the CMR assembly. The metal doping solution includes the ATR catalyst and a WGS catalytic solution, wherein the WGS catalytic solution includes mixed metal oxide nanoparticles suitable for use in a WGS reaction. In certain embodiments, the activated catalytic support includes a layer of ATR nanoparticles and WGS nanoparticles disposed throughout an inner surface layer of the calcined membrane tube. In certain embodiments, the CMR assembly is operable to produce a hydrogen-rich permeate stream and a carbon dioxide-rich retentate stream from a feed stream comprising liquid hydrocarbons, steam, and the oxygen source.

In yet another embodiment of the present invention, the step of obtaining the solution that includes an ATR catalyst producing layered double hydroxides (LDH) precursors through co-precipitation of metal ions in a basic solution, the basic solution having a basic pH and comprising an alkaline metal hydroxide or alkaline metal carbonate and wherein the metal ions include magnesium, nickel and aluminum, heating the LDH precursors at a decomposition temperature above about 500° C., and below a temperature that would result in catalyst sintering, such that the LDH precursors are at least partially decomposed, reducing the metal present in the LDH precursors by contacting with a hydrogen containing gas at a temperature in the range of about 450° C. to about 700° C. such that the layered crystal structures within the LDH precursors collapse to form the ATR catalytic structure, wherein the AIR catalytic structure comprises nanosized mixed oxide particles dispersed throughout, and combining the ATR catalytic structure with an aqueous solution comprising water and metal precursors to form the ATR catalytic solution. Preferably, the LDH precursors include layered crystal structures, and the metal ions include magnesium, nickel, and aluminum.

In one embodiment, the basic solution has a pH value between about 10 and 12. In certain embodiments, the basic solution includes a mixture of NaOH and Na₂CO₃, such that the basic solution has a pH value of about 12. In another embodiment, the metal ions do not include a precious metal. Exemplary precious metals can include platinum, rhodium, gold, iridium, osmium, palladium, rhenium, ruthenium, and platinum. In one embodiment, the second solution has a total cationic concentration of approximately 1.5 M. In another embodiment, the metal ions have an aluminum concentration of about 20 to 35 mol %.

In one embodiment, the ATR nanoparticles and WGS nanoparticles have a surface area between about 100 to 300 m²/g. In another embodiment, the ATR nanoparticles and WGS nanoparticles have diameters in the range of about 40-300 nm. In another embodiment, the ATR nanoparticles and WGS nanoparticles are homogeneously distributed throughout the inner surface layer of the calcined membrane tube. In another embodiment, the ATR nanoparticles and WGS nanoparticles are thermally stable. In one embodiment, the second solution has a total cationic concentration of approximately 1.5 M. In a further embodiment, the hydrogen rich permeate stream is substantially free from carbon monoxide and carbon dioxide.

In one embodiment, the LDH metal reducing step is performed at a temperature within a range from about 500° C. and 600° C.

In another embodiment of the present invention, the step of obtaining an ATR catalytic solution can include:

-   -   a. preparing a first solution having a pH at or above about 10,         the first solution including a hydroxide;     -   b. preparing a second solution having a pH below 7, wherein the         second solution is prepared by combining a mixture of salts with         water, wherein the salts are comprised of cations and anions,         wherein the cations comprise magnesium, nickel, and aluminum,         wherein the second solution has a total cationic concentration         of about 1.5 M;     -   c. mixing the second solution and the first solution together         for a period of time operable to form a sol-gel;     -   d. aging the sol-gel for a period of time to form a formed         solid;     -   e. washing and filtering the formed solid with water until a         generally neutral pH is reached;     -   f. drying the formed solid for a period of time to form a dry         solid;     -   g. calcining the dry solid at a predetermined temperature within         about 500° C. and about 600° C. to form a calcined material; and     -   h. reducing the metal present in the calcined material with a         hydrogen containing gas, at a temperature between about 450° C.         and about 700° C., to form the ATR catalytic structure, the ATR         catalytic structure having nanosized mixed oxide particles         dispersed throughout, wherein the nanosized mixed metal oxides         have diameters in the range of about 40 to about 300 nm.

In certain embodiments, the first solution can include an alkaline metal hydroxide. In another embodiment, the anion can include a nitrate. In another embodiment, the cations can further include an absence of a precious metal. In one embodiment, the first solution can be prepared by combining NaOH with Na₂CO₃ such that the first solution has a pH of about 12. In yet another embodiment, the invention provides for a method for producing a hydrogen-rich permeate stream by introducing a feed stream that includes liquid hydrocarbons, steam, and an oxygen source to any of the CMR assemblies previously described above at an operating temperature and operating pressure, the operating temperature and operating pressure being selected such that the feed stream first undergoes an ATR reaction and a subsequently undergoes a WGS reaction to produce the permeate stream and the retentate stream, wherein the permeate stream includes hydrogen, wherein the retentate stream includes carbon dioxide and unreacted hydrocarbons. In one embodiment, the operating temperature of the CMR assembly is between about 500° C. and about 700° C., and the operating pressure is between about 3 and about 5 bar. In another embodiment, a portion of the permeate stream can be removed from the CMR assembly such that the ATR reaction and the WGS reaction proceed relatively rapidly, such that the conversion of the liquid hydrocarbons to hydrogen exceeds the normal thermodynamic equilibrium value for the operating temperature and operating pressure of the ATR reaction and the WGS reaction without removal of the permeate stream from the CMR assembly.

In another embodiment, the method excludes a step of providing a cooling means to the CMR assembly between the ATR reaction and the WGS reaction.

BRIEF DESCRIPTION OF THE DRAWINGS

These and other features, aspects, and advantages of the present invention will become better understood with regard to the following description, claims, and accompanying drawings. It is to be noted, however, that the drawings illustrate only several embodiments of the invention and are therefore not to be considered limiting of the invention's scope as it can admit to other equally effective embodiments.

FIGS. 1-3 include graphical representations of experimental data collected in accordance with embodiments of the present invention.

FIG. 4 is an embodiment of the present invention.

FIG. 5 is cross sectional view of an embodiment of the present invention.

FIG. 6 is an axial view of an embodiment of the present invention.

FIGS. 7-27 include graphical representations of experimental data collected in accordance with embodiments of the present invention.

DETAILED DESCRIPTION

While the invention will be described in connection with several embodiments, it will be understood that it is not intended to limit the invention to those embodiments. On the contrary, it is intended to cover all the alternatives, modifications and equivalence as may be included within the spirit and scope of the invention defined by the appended claims.

Nano sized catalysts provide advantages over their full size counterparts, particularly in autothermal (ATR) reactions and water-gas-shift (WGS) reactions, in that they increase reaction activity, improve selectivity, improve reactivity towards hydrogen production, and minimize the undesirable methanation reaction.

Carbon formation (as coke), which is a primary disadvantage of a reforming process, is a kinetic issue. As such, coke production depends on the relative reaction rates of possible carbon species reaction alternatives. The reaction mechanism is largely dependent on the hydrocarbon type, operating conditions, and catalyst characteristics. For example, catalyst characteristics can influence the reaction mechanism by increasing water adsorption-dissociation rate on the catalyst and gasification rate with respect to the C—C scission.

Catalyst characteristics are generally determined by their physical-chemistry, composition, structural, and textural properties, such as: active area, metal particle size, metal dispersion, and reducibility. These properties depend on metal-support interaction, and they could be established on different stages of catalyst synthesis. For example, varying the material composition of a precursor, the preparation method and/or the heat treatments (calcination or reduction), can provide desired characteristics of the catalyst for optimum performance.

The present invention provides novel mixed metal oxides that are obtained by thermal decomposition of layered double hydroxides (LDHs) and offers the opportunity to control a catalyst's active site nature and its environment, as well as catalyst texture and stability. LDHs are a unique class of layered materials having positively charged layers and charge balancing anions located in the interlayer region. Typically, LDHs can be synthesized by the co-precipitation of metallic salts with a concentrated alkaline solution. An alternative, method for the preparation of LDHs is through sol gel method. Thermal treatments of the mixed metal oxides resulting from the LDHs prepared by the sol gel method can lead to materials that demonstrate synergetic effects between the elements in the mixed metal oxide structure, and after appropriate activation treatment, give rise to well dispersed metal particles like supported metal catalysts, with the possibility of controlling metal-support interaction during the synthesis stage.

In one embodiment of the present invention, a new catalytic structure that can be used for reforming reactions is provided. In one inventive method of preparing said catalytic structure, several different types of LDHs can be prepared using a sol-gel precipitation method. In one embodiment, two aqueous solutions are prepared; one acidic and one basic. In certain embodiments, the sol is base catalyzed. The acidic solution preferably contains one or metal salts, such as magnesium salts, and specifically nitrates and salts of the same for nickel and aluminum using a desired Al/(Ni+Mg+Al) ratio. The pH of the acidic solution is preferably within the range of about 4 to about 6. In one embodiment, the total cationic concentration of the metal salts in the acidic solution is about 1.5 M. The basic solution can be obtained by mixing suitable amounts of sodium hydroxide and sodium carbonate in order to maintain a ratio of carbonate ions to nickel, magnesium and aluminum ions of around 0.7 and a pH for synthesis of approximately 12.

After the solutions are prepared, they can then be added into a large mixing device and put into mechanical agitation for an appropriate period of time to form a sol-gel. In one embodiment, the appropriate amount of time is determined by measuring the concentration of metal oxide. In one embodiment, 95% concentration of metal oxide is acceptable. At concentrations at or above 95%, a preferred amount of reactant has been consumed, and agitation can be stopped. In one embodiment, ICP-AES analysis can be used to verify the metal oxide concentration. In one embodiment, this mixing step can be for up to about 5 hours. Following the mixing step, the obtained sol-gel is left to age at a temperature of between about 50 and 75° C., alternatively at a temperature of about 60° C. for an appropriate amount of time, which can be up to about 6 hours, alternatively up to about 10 hours, alternatively up to about 15 hours, or greater than 15 hours. During aging, at least a portion of liquid within the sol-gel evaporates. In one embodiment, rapid aging is not preferred as it can detrimentally impact gel characteristics. The resulting solid can then be filtered and washed with distillated water until the wash water has a neutral pH is reached. In certain embodiments the pH is up to about 7.5, alternatively about 7. Water washing is desirable to remove all undesired and converted reactants. Those of ordinary skill in the art will understand neutral pH to including a pH within the range of about 6.5 to 7.5. Next, the resulting washed solid LDH material can be dried at a temperature of about 100° C. for an appropriate amount of time, which can be up to about 5 hours, alternatively up to about 10 hours, alternatively up to about 15 hours. In one embodiment, the LDH material can then be calcined in air at temperatures up to 550° C., alternatively at a temperature of between about 400° C. and 600° C., alternatively at a temperature between about 400° C. and 500° C., alternatively at a temperature between about 500° C. and 600° C., for a period of time, which can be up to about 5 hours, alternatively up to about 8 hours, alternatively up to about 12 hours. The resulting solid product is a catalyst precursor of a mixed metal oxide that includes Ni/Mg/Al. Supported metal catalysts suitable for autothermal reforming reaction of liquid hydrocarbons into hydrogen can be obtained from these precursors after a metal reducing step by contacting with a gas mixture that includes hydrogen, and can also include nitrogen, a temperature of about 500° C., alternatively between about 400° C. and 550° C., for a period of time, which is up to about 5 hours. In one embodiment, the gas mixture includes about 5% molar hydrogen, alternatively between about 1 and 10% molar hydrogen, alternatively between about 5 and 10%, alternatively between about 5 and 15%, alternatively between about 10 and 20% molar hydrogen.

During the metal oxide reduction step, at temperatures greater than about 300° C., the LDL structure will collapse, and in the presence of hydrogen, the metal oxide can be reduced to its elemental state. The collapsed structure was confirmed using XRD (and is shown in FIGS. 1-3). In general, the collapsed structure has an increased density, relative to the starting material, and a porosity that is sufficient for diffusion of reactants into the catalyst to undergo the desired reactions. In certain embodiments, the porosity of the collapsed material can remain consistent with the starting material, having a porosity that is in the range of about 65-70%, which in turn can facilitate the desired reforming reactions.

Experimental Design for Catalytic Structure:

The following synthesis parameters were investigated to obtain catalyst structures in accordance with embodiments of the present invention:

-   -   Al/Mg mole ratio between 0.2-5 in the form of mixed metal         oxides.     -   Calcination temperature: 500° C.-600° C.     -   Reduction temperature: 500° C.     -   Concentration of Hydrogen: 5 to 20% by mole     -   Nickel incorporation method: Co-precipitation simultaneously         with magnesium and aluminum or impregnation on Al—Mg support.

In order to study the synthesis parameter effects on catalytic characteristics of these materials, different series of samples were prepared. In each different sample, only one parameter was changed. The baseline material, identified as CP10C, had the following parameters:

-   -   Nickel content: 10 wt %     -   Cation ratio: Al/(Al+Mg+Ni)=0.20     -   Calcination temperature: 550° C.     -   Reduction temperature: 500° C.     -   Nickel incorporation method: co-precipitation with magnesium and         aluminum.

To determine the Al/Mg ratio effect on catalytic behavior, several catalysts were prepared wherein the Al/Mg ratio was varied between 0.2 and about 5.

To determine the calcination temperature effect on catalytic behavior, several mixed oxides catalysts were prepared wherein the calcination temperatures were varied between about 400° C. and about 800° C.

To determine reduction temperature effect on catalytic behavior, several catalysts were prepared wherein the reduction temperatures was varied between about 450° C. and about 700° C.

To determine the effect of the nickel incorporation method on catalytic behavior, several catalysts were prepared by co-precipitation and by impregnation. Catalysts marked with “LO” were prepared by impregnation, and catalysts marked with a “CP” were prepared by co-precipitation.

The results and characteristics for each of the materials were measured using several different techniques in order to correlate catalytic activity with corresponding structural properties. Catalyst support surface area was measured using the BET technique employing nitrogen physisorption at the temperature of liquid nitrogen in a Quantachrome Autosorb-1C instrument. The percentage of metal loading was measured by Inductively-Coupled Plasma Atomic Emission Spectrometry (ICPAES). X-ray Diffraction (XRD) was carried out using Rigaku Miniflex diffractometer employing a Cu—Kα radiation source (30 KV/15 mA). The average particle size for different phases present on each state of the sample (calcined, reduced or used) was estimated by the Scherre equation, which is reproduced below:

$\tau = \frac{K\; \lambda}{\beta \; \cos \; \vartheta}$

where K is the shape factor, λ is the x-ray wavelength, β is the line broadening at half the maximum intensity (i.e., full width at half maximum) in radians, θ is the Bragg angle; and τ is the mean size of the ordered (crystalline) domains.

Nickel surface area can be measured using well established advanced analytical techniques, such as hydrogen chemisorptions complemented by temperature programmed reduction (TPR) where it is possible to estimate total metal surface area, size of metal particle and metal dispersion.

Temperature programmed reduction (TPR) was carried out using a 5% H₂/N₂ mixed gas containing 5% H₂ and N₂ flowed at 50 mL/min and used to study the reducibility of the calcined samples by means of hydrogen consumption. From TPR curves, the temperature at which a maximum curve appears (nickel reduction temperature) can be used to determine the most efficient reduction conditions. The degree of reduction can be estimated by comparing TPR curves corresponding to calcined and reduced samples. Coke formation on samples during activity test can be determined by analysis of the temperature-programmed oxidation (TPO). Autothermal reforming reaction study was carried out in a down low fixed-bed reactor catalytic system.

Approximately 1 gram of the catalyst was used, having particles the size of about 30-50 mesh, without dilution. The catalyst tested was pre-reduced in an H₂ gas stream (5%) at a temperature of about 500° C. for about 5 hours. Two thermocouples controlled the operation temperature, wherein a first thermocouple was positioned in the oven and the other thermocouple was positioned at the center of the catalyst bed. All reactants were introduced from the top of the reactor. Air was used as a source of oxygen. Two HPLC pumps fed water and hydrocarbon, which were mixed and then evaporated before being introduced into the reaction region. The pressure of the reaction was maintained by a backpressure regulator connected with a precision gauge to read the pressures. Time zero was measured at the point when the reactor contents were heated to the chosen reaction temperature, which usually took about 45 minutes. Gas samples were removed through the gas sampling system throughout the length of the test once the reaction temperature was reached. Effluent from the reactor was cooled in a double pipe condenser to condense the condensable vapors. The gas and liquid samples were analyzed by gas chromatography.

The autothermal reforming reaction was investigated at different reaction conditions as follows:

-   -   Hydrocarbon feed: n-octane,     -   Reaction Temperature: 500° C., 550° C. and 600° C.     -   Total Pressure: 3 bars     -   Weight Hourly Space Velocity (WHSV): 5000 h⁻¹     -   Oxygen/Carbon (molar ratio): 0.5     -   Steam/C (molar ratio): 3

The general reaction procedure included packing the catalysts into the reactor, starting the reactor temperature controller and then, following catalyst reduction, setting the desired temperature condition. Approximately fifteen minutes before the test began, steam was passed through the catalyst bed. Following this, the air flow meter with the water and hydrocarbon pumps were turned on all together at the established conditions.

Each experiment ran for approximately eight hours. The first two hours were conducted at temperature of about 500° C., and then increased to a temperature of about 600° C. for a further two hours, and again increased to a temperature of about 700° C. for two hours, and finally returning to a temperature of about 500° C. for the final two hours. Every thirty minutes, a reformate gas sample was taken for analysis to determine the molar concentrations of H₂, O₂, CH₄, CO and CO₂. Volumetric flow (ml/min) and density (g/ml) of the liquid reformate products were also tested, and were passed through a Gas Chromatography-Flame Ionization Detector (GC-FID) assay.

Two Shimadzu GC-17A Gas Chromatography (GC) units were used to estimate the composition of the product gases and liquid reformate collected from the ATR reaction. The GC units were equipped with thermal conductivity (TCD) and flame ionization (FID) detectors. Specifically, the GC-TCD was used to evaluate the presence of H₂, O₂, N₂, CH₄, CO and CO₂ using a ⅛ inch 6 ft Carbosphere 80/100 packed column. The light and heavy liquid hydrocarbons were analyzed using a GC-FID coupled with a 100 m×0.25 mm ID BPI-PONA capillary column. Liquid product identification was also carried out in a Shimadzu GCMS-QP5050A mass spectrometer equipped with a DB-5 column.

For the GC-TCD method, the injector was held at 100° C. and detector temperature was 150° C. The oven temperature was initially maintained at a temperature of 40° C. for 5 minutes, and was then increased to a temperature of 120° C. at a rate of PC/min. In the case of the GC-FID, the injector was held at 280° C. and detector temperature was 320° C. The oven temperature was initially maintained at a temperature of 60° C. for 5 minutes, and then increased to 280° C. at a rate of 10° C./min.

Referring to FIG. 1, x-ray diffraction spectra for 4 samples prior to calcination are provided. Samples LO1 and LO2 were prepared by impregnation, and samples CP1 and CP2 were prepared by co-precipitation. The samples had compositions of about 20.5% by weight NiO, 5.5% by weight MgO, and 75% by weight Al₂O₃. The samples were all air-dried at 110° C. for approximately 5 to 15 hours. As shown in the x-ray diffraction spectra stacked plot shown in FIG. 1, the individual spectra for each sample are relatively similar, thus demonstrating that the synthetic methods utilizing impregnation and co-precipitation, whether at a pH of 10 or 12, produces material having like crystallographic structure. Additionally, FIG. 1 also displays the LDH structure of different aluminum/magnesium crystallite sizes, along with the crystallinity at different catalyst synthesis conditions.

FIG. 3 shows x-ray diffraction spectra for four calcined catalyst samples having a composition of about 20.5% by weight NiO, about 5.5% by weight MgO, and about 75% by weight Al₂O₃, wherein the samples were calcined at a temperature of about 650° C. for a period of about 8 hours. The materials correspond to the calcined versions of the materials shown in FIG. 1. The spectra show that samples LO2C and CP2C both have peaks at about 38, 46 and 66, which corresponds to mixed metal oxides (as opposed to LDH structures). Sample CP2C also includes a slight peak at about 60, corresponding to metal oxide. In contrast, sample LO1C has peaks at about 38, 42, 46, 63 and 66, and sample CP1C has peaks at about 38, 42, 62, and 66, although the peak at 66 is of a lower intensity.

Based on the experimental results, which are shown in FIGS. 1-3, Applicants surprisingly discovered the following:

(1) Catalyst materials obtained by calcination/reduction of LDH materials characterized by highly dispersed metallic crystallites or grains that are stable inside a matrix with high surface area proved to be suitable catalyst materials for the autothermal reforming of liquid hydrocarbons for hydrogen production.

(2) Catalytic activities test produced nearly total liquid hydrocarbon conversion with large levels of hydrogen produced in total absence of CO production, indicating an excellent balance for use with ATR and WGS combined reactions. This is confirmed by the levels of CO₂ produced. Simultaneously, a sharp decrease in the methanation reaction was found, as well as coke resistance formation that keeps catalyst activity at high level as time on-line progresses.

(3) Synthesis parameters, such as methods for introducing active species, the amount of different individual components, and thermal treatment processes, all contribute to the overall catalytic activity of the materials. As such, these parameters can be further optimized to obtain a material which exhibits high catalytic activity and high resistance to carbon (coke) formation.

(4) Nickel content plays a role on activity as well as on carbon resistance. Nickel incorporated into the catalyst materials by co-precipitation results in more highly and finely dispersed nickel particles than the impregnation method.

(5) The support and its properties seemed to play a key role in the performance of the LDH derived catalysts. For example, magnesium has an effect on the interactions of the metal support, and increasing the aluminum content of the catalyst increases the overall surface area of the catalytic material. Therefore, a preferred Al/Mg ratio can be found from 0.2 to 0.35.

(6) Calcination temperature is preferably high enough to obtain sufficient interaction, but low enough to avoid catalyst sintering. In the experiments conducted, the calcination temperature was kept within the range of 450° C. and 550° C.; however, those of ordinary skill in the art will recognize that other temperatures can be used depending upon the characteristics of the materials used.

(7) Nickel incorporated by co-precipitation results in more highly and finely dispersed nickel particles than the impregnation method. The finer dispersion also leads to a smaller particle size, which yields larger nickel surface area to volume ratio, and improved catalyst performance. Therefore, catalyst performance is strongly linked to the nickel particle size.

(8) Synthesis parameters have an important influence on metal-support interaction. When stronger metal-support interactions are favorable, the catalyst structure is improved. Additionally, catalyst performance is strongly linked to the nickel particle size, as well as the selected support material and its properties.

(9) Nickel incorporated into the catalyst materials by co-precipitation results in more highly and finely dispersed nickel particles than the impregnation method.

As noted previously, prior art catalytic membranes were used to produce and subsequently remove hydrogen through hydrogen permeable metal membranes such as palladium or a palladium alloy. These membranes, in particular palladium or palladium alloys, however, are expensive, sensitive to sulfur compounds, and difficult to sinter with or co-sinter with or sinter onto a catalyst layer. Additionally, such devices typically produced hydrogen only by the WGS reaction.

Some embodiments of the current invention integrate catalysts useful for both the ATR reaction and the WGS reaction, as well as providing a hydrogen permeable membrane that does not include palladium or a palladium alloys, which reduces costs while increasing the overall H₂ yield of the process. In one embodiment, the ATR structure described herein can be incorporated into a catalytic membrane reactor (CMR) assembly, which is operable to perform the ATR reaction, the WGS reaction, and remove hydrogen.

A different type of membrane is the so-called dense protonic ceramic membrane for hydrogen separation and purification. The dense protonic ceramic membranes are based on the use of single-phase and mixed-phase perovskite-type oxidic protonic ceramic membranes for separating or decomposing hydrogen containing gases or other compounds to yield a higher value product. As with the hydrogen permeable metal membranes such as palladium or a palladium alloys, to date, there has not been any report suggesting the use of the dense protonic membranes in a one-step hydrocarbon to hydrogen reforming reaction, WGS reaction and gas purification system.

It is highly desirable to develop membrane reactors that are capable of converting liquid hydrocarbons into high purity hydrogen gas in a single step.

In one embodiment of the invention, a method for the production of hydrogen by oil reforming processes reduces the overall cost of producing high quality hydrogen from liquid oil, as compared to the prior art processes. In one embodiment, the method can include a gasification, steam reforming, partial oxidation, autothermal reforming, or like step, depending on the characteristic of the oil feed processed to obtain synthesis gas. This synthesis gas requires subsequent cleaning as it is shifted to produce additional hydrogen gas. In one embodiment, one or more of these steps can be combined to improve efficiency. In certain embodiments of the present invention, additional novel technologies, such as membrane separation and catalytic reactors, have been developed that can help to solve these needs. Additionally, some embodiments of the present invention are also operable to remove unwanted products, such as CO₂, to thermally provide one stream that can be used in a secondary process, such as in enhanced oil recovery from depleted oil reservoirs.

In one embodiment, methods for producing hydrogen from alternate hydrocarbon sources of oil (such as, gasoline, kerosene, diesel, petroleum coke, heavy residues, and the like), involves the step of first reacting oil with oxygen and/or steam to produce a gas mixture that includes carbon monoxide, carbon dioxide and hydrogen. The carbon monoxide can then react with steam to produce additional hydrogen and CO₂. Finally, the hydrogen and CO₂ can be separated, either by removing the CO₂ from the mixture or by removing hydrogen from the mixture. The removal of at least a portion of the hydrogen gas will advantageously shift the reaction equilibrium toward the product side, allowing a lowering of the reaction temperature and use of a decreased amount of steam. An optional cleaning step can also be employed, but CO contamination can be controlled to make such contamination negligible. For example, concentrations of CO as low as 0.001% can be obtained, making the hydrogen substantially free of carbon monoxide. In certain embodiments, all of the hydrogen produced can be removed.

The combination of reaction and separation processes for the CMR assembly built in accordance with embodiments of the present invention, offers higher conversion of the reforming reaction at lower temperatures due to the step of removing hydrogen gas from the steam reforming and WGS equilibrium reactions. Thus, depending on the feed oil composition used, a membrane reactor as part of an engineering process can allow one step reforming and/or partial oxidation with WGS reaction and parallel hydrogen separation. Unlike conventional prior art processes, the CMR assembly equipped with the catalysts described herein benefits from high pressure operation due to the increased hydrogen partial pressure differences across the membrane, which act as the driving force for hydrogen permeation. For example, the pressure on the permeate side can be atmospheric or under vacuum. When a higher pressure on the retentate side is applied, the pressure difference across the membrane acts as a driving force for hydrogen to permeate through the membrane. The higher the pressure difference, the higher the amount of hydrogen permeating through the membrane. Those of ordinary skill in the art will recognize that the mechanical property of the membrane used will create a practical limit as to the pressure that can be applied on the retentate side.

Another embodiment of the present invention discloses a method of manufacturing a catalytic coated silica membrane for the conversion of liquid petroleum hydrocarbon fuels into high purity hydrogen. The embodiment includes the step of providing a membrane tube, which includes an outer surface covered with an active silica layer that is highly permeable to hydrogen. A mixed metal oxide catalyst, which can include at least one metal selected from the group consisting of rhodium, platinum, nickel, ruthenium, palladium, rhenium, iridium, and combinations thereof, can be deposited within the pores of the alumina framework of the membrane tube. During use, air, steam, and liquid hydrocarbons are transported through the membrane and are in intimate contact with the metal sites. Following activation of the catalyst membrane, the feed components react and form hydrogen through a combination of ATR and WGS reactions. High purity hydrogen can be produced by separation of the hydrogen gas from the product mixture through the hydrogen permeable membrane deposited on the CMR assembly outer surface. Certain embodiments of the present invention bring a number of benefits to hydrogen production from liquid petroleum hydrocarbon fuels. These improvements can include high conversion of the liquid hydrocarbons, high molar yield of the hydrogen produced, low molar yield of the residual methane and low catalyst deactivation as a result of the shifting of reaction equilibrium to favor the forward reaction to nearly 100% at a much lower operating temperature range between about 500° C.-550° C. Typical hydrogen purity in this one-step conversion of liquid petroleum hydrocarbon to hydrogen can range from about 96 to 99% molar concentration, alternatively at least about 97% molar concentration, alternatively at least about 98% molar concentration, or alternatively between about 97 and 99% molar concentration.

In one embodiment, a Catalytic Membrane Reactor (CMR) assembly in accordance with an embodiment of the present invention can be selectively permeable to hydrogen and produce a hydrogen-rich permeate product stream on the permeate side of the membrane and a carbon dioxide rich product retentate. The CMR assembly can be used to produce a hydrogen-rich permeate product stream that is greater than about 99% by volume hydrogen. The CMR assembly can be a composite ceramic material having an outer hydrogen transport and separation layer, which in one embodiment is a metal doped silica. The CMR assembly can be also composed of one or more inner catalytic layers. The ATR and WGS reactions occur on the inner metal layers of the CMR assembly and the produced hydrogen can be transported and removed through the outer metal-doped silica layer.

In one embodiment, the metal catalysts are capable of catalyzing the conversion of hydrocarbon fuels to hydrogen and carbon oxides (CO and CO₂). In one embodiment, the catalyst can include one or more of the following metals: nickel, ruthenium, platinum, palladium, rhodium, rhenium, and/or iridium.

The CMR assembly can include a stainless steel vessel that surrounds the tubular support and is positioned between a pair of high temperature material shells. In one embodiment, the high temperature material shells can help to provide sealing, manifolding, expansion support, separated regions for the catalytic reactions, delivery of pressurized feedstock, support of the membrane, and removal of product gases.

In accordance with one embodiment of the present invention, the stainless steel vessel was constructed of 316 grade stainless steel. In an exemplary embodiment, a cylindrical α-alumina tube having an outer diameter of about 10 mm and an inner diameter of about 8 mm with an average pore size of 1.3 micro meters and an approximate porosity of 0.55 was used as ceramic tube support for the membrane. For the preparation of the active catalytic sites and the membrane separation pores, the following procedure was, adopted:

First, the α-alumina ceramic tube was soaked in a boehmite sol-gel, having a concentration in the range of about 5 to 10% by weight boehmite. After removing the excess boehmite by drip drying, the ceramic tube was dried by natural convection at room temperature for several hours and then at about 110° C., for up to about 10 hours. It was followed with calcination at a temperature of about 500° C. that resulted in the bimodal distribution for the original α-alumina structure into alpha and gamma phases. During the calcination step, the nitrates and other gaseous oxides were evaporated and converted to the metal oxide form of the active metals and support structure (e.g., NiO, MgO, and Al₂O₃). For the materials used, the preferred calcination temperature was between 500° C. and 800° C. At temperatures above 800° C., it was discovered that the metal oxide structure changed to a dense, low surface area material, which greatly reduced its catalytic activity. To introduce the catalyst metal active sites to the tubular structure, the ceramic tube was soaked in a solution containing salts of metal species, such as nickel, ruthenium; platinum, palladium, rhodium, rhenium, iridium, and combinations thereof, at the appropriate concentration. Drying and calcination steps were subsequently performed, resulting in a uniform metal distribution within the core of the ceramic tubular structure. The final step was to dope the outer surface of the metal loaded catalytic ceramic tube with a silica colloidal sol-gel to produce an even thickness and uniform pore size hydrogen permeable layer. In one embodiment, this process can be repeated several times to remove large pores that might result in pinholes in the final membrane. In one embodiment, the silica colloidal sols were coated on the ceramic tube by a hot coating method in which the tube was first heated to a temperature of up to around 180° C. The tube was subsequently and quickly contacted with a wet cloth containing the sols. This hot coating method helped make the sol dry more quickly, preventing the sol from penetrating deep into the pores. The catalytic membrane can be cut in pieces and then characterized by Scanning Electron Microscopy (SEM), nitrogen adsorption, porosimetry and hydrogen adsorption.

In order to test the hydrothermal stability of the silica membrane, a stability experiment was carried out at about 500° C. using several different molar ratios of steam and liquid hydrocarbon. The permeability-selectivity of the ceramic tube to hydrogen was measured at timed intervals. In general, a very slow drop in the permeation characteristics due to humidity was observed. Typically, at high temperature, silica interacts with steam causing densification of the material. Within the temperature ranges used in the experiment (e.g., between about 500° C. and about 600° C.), the membrane did not show any substantial change in its permeation properties. In addition, the influence of the molar ratio of water (steam) to hydrocarbon on liquid hydrocarbon conversion within the temperature range of 500° C. to 550° C. showed that the conversion was enhanced at high steam to hydrocarbon molar ratios, such as a steam to hydrocarbon molar ratio of greater than about 3:1, or alternatively between about 2:1 and about 3:1. The hydrocarbon feed reacted very effectively with steam and air through the ATR reaction steps. A fraction of the CO produced during the ATR reaction subsequently reacted with steam in the WGS reaction, leading to increased hydrogen yield. In-situ removal of hydrogen by the membrane further enhanced conversions of both of these reactions. In addition, enhancement in the rate of CO removal by the WGS reaction can reduce coke deposition caused by the so-called Boudouard reaction.

In FIG. 4, CMR assembly 10 includes: stainless steel vessel 12, shells 14, ceramic tube 20, feed stream inlet 30, retentate output 40, sweep stream inlet 50, and permeate output 60. The feed stream (not shown), which includes liquid hydrocarbons, steam, and the oxygen source, enters CMR assembly 10 thru feed stream inlet 30. The feed stream then moves into ceramic tube 20 where it undergoes both ATR and WGS reactions, thereby forming hydrogen and carbon dioxide. The hydrogen that permeates thru the permeable membrane of ceramic tube 20 is removed by a sweep gas, such as nitrogen, argon, steam, and combinations thereof that enters thru sweep stream input 50 and exits permeate output 60.

FIG. 5 shows an embodiment in which ceramic tube 20 has ATR layer 22 and WGS layer 24 disposed within the tube in two separate layers. Those of ordinary skill in the art, however, will recognize that the ATR catalysts and WGS catalysts can also be disposed within the same layer. In the embodiment shown in FIG. 2, the feed stream enters ceramic tube 20 where it reacts with ATR catalysts disposed in ATR layer 22. This reaction converts the hydrocarbon, oxygen, and steam in the feed stream into hydrogen gas and carbon monoxide gas. The carbon monoxide can react with additional steam and the WGS catalysts disposed in WGS layer 24 to form carbon dioxide and, additional hydrogen gas. The hydrogen gas then travels radially outward through the pores of γ-alumina layer 26 and then through membrane 28. The carbon dioxide gas cannot permeate membrane 28, and exits ceramic tube 20 on the retentate side of membrane 28. Unconverted hydrocarbons and carbon dioxide exit ceramic tube 20 through retentate output 40 of FIG. 4.

FIG. 6 is an axial view of ceramic tube 20 as shown in FIG. 5 along line 6-6.

Experimental Design for CMR Assembly:

Commercial alumina tubes (obtained from Noritake, Japan) of 100 mm length and 10 mm ID were used for the CMR assembly. The tubes include α-alumina having a porosity of about 30% and average pre size of about 0.5-1 μm. A γ-alumina layer having a pore size of about 4 nm was disposed on the outer surface of the tubes. A metal doped sol-gel was prepared by mixing 120 g of tetraethyl orthosilicate (TEOS) in 600 g ethanol to form a solution. An acid solution was then synthesized by dissolving 14.84 g cobalt nitrate hexahydrate (Co(No₃)₂.6H₂O) in 51.77 g of 30% aqueous H₂O₂. Subsequently both solutions were vigorously mixed together by stirring for about 3 hours in ice-cooled bath. The tubes were then externally coated with a stable Si—Co—O solution using a controlled immersion time of 1 minute and withdrawn speed of 2 cm/min. Sintering was then carried out at about 600° C. for about 4 hours at a heating rate and a cooling rate of 0.7° C./min.

The internal area of the alumina tube was wetted with a sol-gel that includes a boehmite solution having a concentration in the range of 5-10 wt % of aluminum. Excess solution was wiped off, and the tube was dried for several hours at a temperature of about 110° C., and then fired at a temperature of about 500° C. for about 8 hours, which resulted in an inlet tube wall of γ- and α-alumina having a bimodal distribution. Subsequently, this internal layer of the tube was soaked with chloroplatinic acid and rhodium chloride solutions (0.5 wt % platinum and 2.5 wt % rhodium, respectively), followed with drying, calcination, and reduction under hydrogen to finely disperse the active metal particles over the γ- and α-alumina pores.

In one embodiment for the preparation of the chloroplatinic acid and rhodium chloride solutions, the following procedure was used: TEOS was mixed together with the metal solutions, water and ethanol according to the following:

-   -   TEOS: 0.9 parts     -   Pt—Rh: 0.5 to 2.5 parts     -   Water: 4 parts     -   HNO₃: 0.01 parts     -   Ethanol: 10 parts         Afterwards, the resulting solution was hydrolyzed for about 12         hours at room temperature. After adding an appropriate amount of         0.1 M solution of nitric acid, the solution was left at room         temperature for about 5 hours to convert into a colloidal sol         solution. It was then used to coat the internal wall of the         membrane tube.

A silica metal doped hydrogen separation layer having a thickness of about 1 μm was formed on the external wall of the membrane tube. Additionally, an internal, highly dispersed Rh—Pt catalytic layer, having a metal dispersion of about 65%, was impregnated on the bimodal layer (which includes α- and γ-alumina) to act as a catalytic layer for the simultaneous ATR and WGS reactions to occur in the internal wall of the membrane tube.

Experimental Results of CMR Assembly:

A set of initial experiments were conducted using the CMR assembly described above and shown in FIGS. 4-6, and a commercially available autothermal catalyst (FCR-71D autothermal catalyst provided by Sud Chemie). One gram of the commercially available catalyst was used under similar experimental conditions tested on a fixed bed reactor (FBR) during catalyst selection: Temperature of 500° C.; Pressure of 3 bars; oxygen:carbon ratio of 1:2; steam:carbon ratio of 3:1; and a hydrocarbon feed of commercial gasoline. FIG. 7 shows the total gas product distribution at the end of both the retentate and the permeate side of the membrane. Hydrogen concentration on the permeate side was observed to be as high as 92% by volume. A 77 wt % recovery of hydrogen was obtained, with the remainder of the product stream being a mixture of carbon monoxide, carbon dioxide, methane and unconverted oxygen. A total conversion of about 98% of commercial gasoline was obtained.

The hydrogen yield produced using a fixed bed reactor system and when using a CMR assembly was compared and can be seen in FIG. 8. As shown in FIG. 8, embodiments of the present invention utilizing the CRM assembly provide a distinct advantage over fixed bed reactors due to shifting the conditions of the reaction equilibrium.

In FIGS. 9 and 10, the temperature was increased to 550° C. Notably, the CMR reactor had a higher selectivity of hydrogen (about 15% more) as compared to the fixed bed operation. Additionally, as shown by comparing FIG. 9 and FIG. 10, the CMR operation reduced the production of methane by approximately 40%, as compared with the fixed bed reactor.

FIG. 11 shows comparisons of the average concentrations of hydrogen, carbon monoxide and methane in the product streams for fixed bed operation and CMR operation as function of temperature (500° C. and 550° C.). Comparing both fixed bed reactor and CMR operations, an increased amount of hydrogen is produced at an operating temperature of 500° C. than is produced at an operating temperature of 550° C. Additionally, at increased temperatures, the reduction in methane produced is very significant. On the retentate side of the reaction, analysis of the CO demonstrates nearly the same values for both operations.

The strength of the silica membrane and the hydrogen separation through the retentate was tested for both the CMR and FBR reactors at 600° C., using the same reaction parameters as provided above with respect to FIGS. 7-9. The experiment was conducted for about 6.5 hours, however, after completion of the experiments, leaks were observed through the membrane and through the graphite sealing. FIG. 12 represents a comparison of the results on hydrogen selectivity are compared as function of temperature and type of reactor used. As shown in FIG. 12, hydrogen is produced in amounts greater than the thermodynamic equilibrium conditions at temperatures of 500° C. and 550° C. Additionally, both CMR and fixed bed reactors show decreased hydrogen selectivity with increased temperature.

FIGS. 13 and 14 compare the selectivity of two reactors to methane and carbon monoxide. When using CMR operation, the methane yield is significantly reduced compared with the values for FBR. This behavior can be attributed to the fact that in using the CMR device, the thermal cracking reaction of the fuel and the Boudouard reaction that causes methanation, are inhibited because hydrogen is continually being removed through the silica membrane, which in turn causes more carbon monoxide to be consumed. On the other hand, the carbon monoxide yield between the two operation modes remains practically unchanged. As such, CMR operations increase yields of hydrogen, reduce yields of methane, and have a negligible effect on carbon monoxide production.

Table I presents the comparison of gasoline conversion, total hydrogen produced and the percentage of hydrogen recovered through the membrane as function of the reaction temperature. Increased reaction temperature favors the hydrogen recovery from the membrane, although the total hydrogen yield decreased.

TABLE I Composition Production for CMR as a Function of Temperature Temperature Gasoline Hydrogen % Hydrogen (Celsius) Conversion (%) produced (mol %) Recovered 500 89 72 90 550 94 64 94

FIG. 15 shows the levels of catalyst deactivation for the two types of reactors. As shown in FIG. 15, carbon deposition on the catalyst surface is lower for CMR operation as compared with FBR operations. Additionally, carbon deposition on the catalyst surface is nearly independent of temperature for CMR operation, contrasting with FBR operation where carbon deposition increased by nearly 100%, as the temperature was increased from about 500° C. to about 600° C.

Coke deposit selectivity can be seen in FIG. 16, which shows the temperature programmed oxidation (TPO) analysis of the coked catalysts using CMR and FBR operations. The results indicate that coke deposition from catalysts used in CMR operation mainly covers the support sites of the catalysts, thereby leaving the metal active sites clean and free from deactivation. FBR, on the other hand, shows deposition on support sites and also on metal sites and in the vicinity of metal-support sites. This coke deposition can break the reaction chain to produce hydrogen as reflected by the high methane and light unsaturated hydrocarbons that were found during FBR operations.

FIGS. 17 and 18 show the gas selectivity for permeate and retentate for the membrane sample CMR-1. In this case, hydrogen purity in the permeate was greater than about 95 mol %. Relatively low amounts of CO and methane were produced, which is an indication that the methanation reaction is suppressed and the WGS reaction is enhanced.

FIGS. 19 and 20 show the gas selectivity for permeate and retentate for membrane sample CMR-2. CMR-2 is a tube having similar physical characteristics to that of CMR-1, and it was used to show reproducibility. Similar to CMR-1, CMR-2 displayed a high hydrogen purity in permeate of around 90 mol %. CMR-2 also showed good membrane stability and very low production of CO and methane, which is an indication that the methanation reaction is suppressed and the WGS reaction is enhanced.

FIGS. 21 and 22 show the gas selectivity for permeate and retentate for membrane sample CMR-3. CMR-3 is a tube having similar physical characteristics to that of CMR-1 and CMR-2; however, it was from a different supplier, and was used to show reproducibility. Similar to CMR-1 and CMR-2, use of CMR-3 resulted in a high hydrogen purity in permeate of around 90 mol %. CMR-3 also showed good membrane stability and very low production of CO and methane, which is an indication that the methanation reaction is suppressed and WGS reaction is enhanced.

FIGS. 23-25 show the hydrogen purity concentration on permeate and retentate for each of the 3 membranes: CMR-1, CMR-2 and CMR-3. FIGS. 23-25 show that CMR-1 has the largest differences in hydrogen purity between the permeate and the retentate, indicating that CMR-1 is the membrane with the best hydrogen recovery rates (e.g., about 82%), which is shown in FIGS. 26 and 27.

There are various alternative uses for the CMR assembly as constructed. For example the membrane system can be used as a hydrogen extractor for removing hydrogen from refinery gas streams such as the catalytic cracker off gas, hydrodesulfurization gas, etc. Other uses can also include hydrogenation, dehydrogenation, fuel cells, and the like.

By integrating a hydrogen perm-selective silica layer with a reforming catalytic layer, an efficient and compact CMR assembly for reforming liquid hydrocarbon fuels into hydrogen has been shown. The system shows increased performance in the reforming of liquid hydrocarbons, at comparatively lower operating temperatures and lower steam to carbon molar ratios, than is typically the case for conventional fixed-bed reforming processes. The process efficiency, to a large extent, depends on various process parameters. Under optimized conditions, a nearly 30% improvement from the equilibrium conversion levels was achieved as a result of continuous hydrogen removal from the product stream through the CMR assembly that employs a hydrogen permeable silica membrane integrated with the catalyst layer. The system offers a promising alternative to conventional hydrogen permeable membrane reactors that are typically packed with either reforming or WGS catalysts.

Use of terms such as “first” or “second” are strictly for labeling purposes and do not connote order of operations.

While the invention has been described in conjunction with specific embodiments thereof, it is evident that many alternatives, modifications, and variations will be apparent to those skilled in the art in light of the foregoing description. Accordingly, it is intended to embrace all such alternatives, modifications, and variations as fall within the spirit and broad scope of the appended claims. The present invention may suitably comprise, consist or consist essentially of the elements disclosed and may be practiced in the absence of an element not disclosed. 

1. A catalytic membrane reactor assembly comprising: a ceramic tubular support having a porous structure; an autothermal reforming (ATR) catalytic structure disposed throughout an inner surface layer of the porous structure of the ceramic tubular support, the ATR catalytic structure comprising mixed metal oxides; a water-gas-shift (WGS) catalytic structure also disposed throughout the inner surface layer of the porous structure of the ceramic tubular support, the WGS catalytic structure comprising mixed metal oxides, wherein the ATR and WGS catalytic structures are operable to react with a feed stream comprising liquid hydrocarbon, steam, and an oxygen source to form hydrogen through a combination of autothermal reforming and water-gas-shift reactions; a γ-alumina layer disposed on an outer surface of the ceramic tubular support, the γ-alumina layer having a porous structure; and a membrane layer disposed on an outer surface of the γ-alumina layer, the membrane layer being selectively permeable to hydrogen, wherein the catalytic membrane reactor assembly is operable to produce a permeate stream and a retentate stream, wherein the permeate stream consists essentially of hydrogen gas, and the retentate stream comprises carbon dioxide.
 2. The catalytic membrane reactor assembly of claim 1, further comprising: a stainless steel vessel having the ceramic tubular disposed therein, the stainless steel vessel having a generally cylindrical shape; a pair of shells, wherein each shell is disposed on an end of the stainless steel vessel, the pair of shells operable to form an airtight seal with the stainless steel vessel; a feed input operable to receive the feed stream, wherein the feed input is in fluid communication with the inner surface layer of the ceramic tubular support; a sweep stream input operable to receive a gaseous sweep stream; a permeate output operable to receive the permeate stream; and a retentate output operable to receive the retentate stream.
 3. The catalytic membrane reactor assembly of claim 1, wherein the membrane layer comprises a silica layer that is doped with metal.
 4. The catalytic membrane reactor assembly of claim 3, wherein the metal is selected from the group consisting of cobalt, iron, niobium, and combinations thereof.
 5. The catalytic membrane reactor assembly of claim 1, wherein the ATR catalytic structure and the WGS catalytic structure are each comprised of nanoparticles.
 6. The catalytic membrane reactor assembly of claim 1, wherein the ATR catalytic structure comprises mixed metal oxides, wherein the mixed metal oxides include a metal selected from the group consisting of rhodium, platinum, nickel, ruthenium, palladium, rhenium, iridium, gold, osmium, and combinations thereof.
 7. The catalytic membrane reactor assembly of claim 1, wherein the WGS catalytic structure comprises mixed metal oxides, wherein the mixed metal oxides include a metal selected from the group consisting of copper, zinc, iron, and combinations thereof.
 8. The catalytic membrane reactor assembly of claim 1, wherein the ATR catalytic structure does not include a precious metal.
 9. The catalytic membrane reactor assembly of claim 1, wherein the WGS catalytic structure does not include a precious metal.
 10. The catalytic membrane reactor assembly of claim 1, further comprising the absence of a reformate cooler.
 11. The catalytic membrane reactor assembly of claim 1, wherein the ceramic tubular support comprises an α-alumina tube.
 12. The catalytic membrane reactor assembly of claim 11, wherein the α-alumina tube has a porosity of about 30 to 40%.
 13. The catalytic membrane reactor assembly of claim 11, wherein the α-alumina tube has an average pore size of about between about 0.5 and 1 micron.
 14. The catalytic membrane reactor assembly of claim 1, wherein the γ-alumina layer has an average pore size of about 4 nm.
 15. A method for formulating a catalytic membrane reactor assembly having an autothermal reforming (ATR) catalytic structure, the method comprising the steps of: introducing an α-alumina membrane tube into a boehmite sol-gel for a sufficient period of time to allow the boehmite sol-gel to adequately coat the α-alumina membrane tube; removing the boehmite sol-gel soaked α-alumina membrane tube from the boehmite sol-gel and allow the α-alumina membrane tube to dry; calcining the α-alumina membrane tube at a temperature within a range from about 450° C. to 600° C. until a bimodal distribution of α-alumina and γ-alumina phases form to yield a calcined membrane tube; obtaining an ATR catalytic solution comprising an ATR catalyst, said ATR catalyst comprising mixed metal oxide nanoparticles; coating the calcined membrane tube with a metal doping solution to form an activated catalytic support, the metal doping solution comprising the ATR catalytic solution and a WGS catalyst solution, the WGS catalyst solution comprising mixed metal oxide nanoparticles, the activated catalytic support having a layer that includes ATR nanoparticles and WGS nanoparticles disposed throughout an inner surface layer of the calcined membrane tube; and coating an outer surface of the activated catalytic support with a silica colloidal sol-gel to produce a silica containing hydrogen permeable layer on the outer surface of the activated catalytic support to produce the catalytic membrane reactor assembly, wherein the catalytic membrane reactor assembly is operable to produce a hydrogen rich permeate stream and a carbon dioxide rich retentate stream through a combination of an autothermal reformation reaction and a water-gas-shift reaction from a feed stream comprising liquid hydrocarbons, steam, and oxygen.
 16. The method of claim 15, wherein the step of obtaining the ATR catalytic solution comprises the steps of: producing layered double hydroxides (LDH) precursors through co-precipitation of metal ions from a basic solution, the basic solution having a basic pH and comprising an alkaline metal hydroxide or an alkaline metal carbonate, the LDH precursors having layered crystal structures, the metal ions comprising magnesium, nickel, and aluminum; heating the LDH precursors at a decomposition temperature of above about 500° C. and below a sintering temperature that would result in catalyst sintering such that the LDH precursors are at least partially decomposed; and reducing the metal of the LDH precursors by contacting with a hydrogen containing gas at a temperature of between about 450° C. and 700° C., wherein the step of reducing the LDH precursors metal results in the collapse of the layered crystal structures within the LDH precursors to form an ATR catalytic structure, the ATR catalytic structure comprising nanosized mixed metal oxide particles dispersed throughout, the nanosized mixed metal oxide particles having diameters in a range of about 40-300 nm; and combining the ATR catalytic structure with an aqueous solution comprising water and metal precursors to form the ATR catalytic solution.
 17. The method of claim 16, wherein the basic solution has a pH between about 10 and
 12. 18. The method of claim 16, wherein basic solution further comprises an aqueous mixture of NaOH and Na₂CO₃, such that the basic solution has a pH of about
 12. 19. The method of claim 16, wherein the metal ions have an aluminum concentration of between about 20 mol % and 35 mol %.
 20. The method of claim 16, wherein the decomposition temperature is between about 500° C. and 600° C.
 21. The method of claim 15, wherein the hydrogen rich permeate stream is substantially free from carbon monoxide and carbon dioxide.
 22. The method of claim 15, wherein the ATR nanoparticles and WGS nanoparticles have a surface area between about 100 and 300 m²/g.
 23. The method of claim 15, wherein the ATR nanoparticles and WGS nanoparticles are homogeneously distributed throughout the inner surface layer of the calcined membrane tube.
 24. The method of claim 15, wherein the ATR catalytic solution has a total cationic concentration of about 1.5 M.
 25. The method of claim 15, wherein the step of obtaining an ATR catalytic solution comprises the steps of: (a) preparing a first solution having a pH at or above about 10; (b) preparing a second solution having a pH below 7, wherein the second solution is prepared by combining a mixture of salts with water, wherein the salts are comprised of cations and anions, wherein the cations comprise magnesium, nickel, and aluminum, wherein the second solution has a total cationic concentration of about 1.5 M; (c) mixing the second solution and the first solution together to form a sol-gel; (d) aging the sol-gel to form a formed solid; (e) washing and filtering the formed solid with water until a neutral pH is reached; (f) drying the formed solid to form a dry solid; (g) calcining the dry solid at a predetermined temperature within about 500° C. and about 600° C. to form a calcined material; and (h) reducing the metal in the calcined material to a metal reduction step by contacting the calcined material with a hydrogen containing gas at a temperature of between about 450° C. and 700° C. to form the ATR catalytic structure, the ATR catalytic structure having nanosized catalytic mixed oxide particles dispersed throughout, wherein the nanosized mixed metal oxides have diameters in a range of about 40-300 nm.
 26. The method of claim 25, wherein the anions comprise nitrate.
 27. The method of claim 25, wherein the cations further comprise an absence of a precious metal.
 28. The method of claim 25, wherein the first solution of step (a) is prepared by combining NaOH and Na₂CO₃ such that the first solution has a pH of about
 12. 29. A method for producing a hydrogen rich permeate stream, the method comprising the steps of: introducing a feed stream comprising liquid hydrocarbons, steam, and oxygen to the catalytic membrane reactor assembly as claimed in claim 1 at an operating temperature and operating pressure, the operating temperature and operating pressure being selected such that the feed stream undergoes an autothermal reforming reaction and a subsequent water-gas-shift reaction to produce a permeate stream and a retentate stream, wherein the permeate stream comprises hydrogen, wherein the retentate stream comprises carbon dioxide and unreacted hydrocarbons, and wherein the operating temperature of the catalytic membrane reactor assembly is within a range of about 500° C. and about 800° C. and the operating pressure of the catalytic membrane reactor assembly is within a range of about 3 and about 5 bar; and removing at least a portion of the permeate stream from the catalytic membrane reactor assembly such that the ATR reaction and the WGS reaction proceed relatively rapidly, such that the conversion of the liquid hydrocarbons to hydrogen exceeds the normal thermodynamic equilibrium value for the operating temperature and operating pressure of the ATR reaction and the WGS reaction without removal of the permeate stream from the catalytic membrane reactor assembly.
 30. The method of claim 29, wherein the method further comprises an absence of the step of providing a cooling means to the catalytic membrane reactor assembly of claim 1 between the ATR reaction and the WGS reaction. 